chery Arauca (2009) Workshop manual

2009
CHERY
A1
Service Manual

FOREWORD

This manual contains on-vehicle service
and diagnosis procedures for the Chery A1.

A thorough familiarization with this manual
is important for proper repair and
maintenance. It should always be kept in a
handy place for quick and easy reference.

The contents of this manual, including
drawings and specifications, are the latest
available at the time of printing. As
modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Chery dealers. This manual
should be kept up-to-date.

Chery Automobile Company, Ltd. reserves the
right to alter the specifications and
contents of this manual without obligation
or advance notice.

All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or mechanical—
including photocopying and recording and the
use of any kind of information storage and
retrieval system—without permission in
writing.

NOTE:

This A1 service manual only applies to the follow­ing engines and transaxles:

• 1.3L with M/T

• 1.3L with AMT

Chery Automobile Company, Ltd.

Wuhu, Anhui Province, CHINA

CONTENTS

Title Section

GENERAL INFORMATION

01

ENGINE

02

ELECTRONIC ENGINE CONTROLS

03

FUEL DELIVERY

04

STARTING & CHARGING

05

COOLING

06

EXHAUST

07

TRANSAXLE

08

DRIVELINE & AXLE

09

SUSPENSION

10

STEERING

11

BRAKES

12

HEATING & AIR CONDITIONING

13

RESTRAINTS

14

BODY & ACCESSORIES

15

WIRING

16

ALPHABETICAL INDEX

AI

© 2009 Chery Automobile Co., Ltd.

PRINTED NOVEMBER, 2009

GENERAL INFORMATION

01

CONTENTS

page

Service Information . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Vehicle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9

Electrical Circuit Diagnosis Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15

Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20

SERVICE INFORMATION

HOW TO USE THIS MANUAL

01-2
Topics 01-2
Service Procedures 01-2
Diagnostic Procedures 01-2
Specifications 01-2

VEHICLE SERVICE PREPARATION

01-3
Preparation For Vehicle Service 01-3
Tools and Testing Equipment 01-3
Special Tools 01-3
Disconnection of the Negative Battery
Cable 01-4

PROPER SERVICE PRACTICES

01-5
Removal of Parts 01-5
Component Disassembly 01-5
Inspection of Parts 01-5
Arrangement of Parts 01-6
Cleaning of Parts 01-6
Component Reassembly 01-6
Adjustments 01-7
Rubber Parts and Rubber Tubing 01-7
Hose Clamps 01-8
Vise 01-8
Dynamometer 01-8

01

01–1

Chery Automobile Co., Ltd.

HOW TO USE THIS MANUAL

Topics

This manual contains procedures for performing all required service operations.

The procedures are divided into three basic operations:

• Removal/Installation

• Disassembly/Assembly

• Inspection

Service Procedures

Most repair procedures begin with an illustration. It identifies the components, shows how the parts fit together and
describes visual part inspection. Removal & Installation procedures have written instructions.

Service procedures include the following elements:

• Detailed removal & installation instructions

• Integrated torque specifications

• Integrated illustrations

• Component specifications

Diagnostic Procedures

The diagnostic procedures are divided into the following two groups:

Diagnostic Trouble Codes (DTC)

• DTCs are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diag­nostic inspection to quickly and accurately diagnose the malfunction.

Diagnostic Symptoms

• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.

Specifications

This manual contains specifications that are divided into the following groups:

• Torque specifications

• Clearance specifications

• Capacity specifications

01–2

Chery Automobile Co., Ltd.

VEHICLE SERVICE PREPARATION

Preparation For Vehicle Service

• Always be sure to cover fenders, seats and floor
areas before starting work.

Tools and Testing Equipment

• Be sure that all necessary tools and measuring
equipment are available before starting any work.

• Inspect the vehicle and reference any needed ser­vice information before starting any work.

Special Tools

• Use special tools when they are required.

BESM010004

BESM010005

BESM010006T

01

01–3

Chery Automobile Co., Ltd.

Disconnection of the Negative Battery Cable

• Before beginning any electrical work, turn the igni­tion switch to LOCK, disconnect the negative bat­tery cable and then wait two minutes to allow the
backup supply of the air bag diagnostic monitor unit
to deplete its stored power.

• Disconnecting the battery cable deletes the memo­ries of the clock, audio and DTCs, etc. Therefore, it
is necessary to verify those memories before dis­connecting the cable.

VEHICLE SERVICE PREPARATION

PZSM010001

01–4

Chery Automobile Co., Ltd.

PROPER SERVICE PRACTICES

Removal of Parts

• While correcting a problem, also try to determine its
cause. Begin work only after first determining which
parts and subassemblies must be removed and dis­assembled for replacement or repair. After removing
the part, plug all holes and ports to prevent foreign
material from entering.

Component Disassembly

• If the disassembly procedure is complex requiring
many parts to be disassembled, make sure that all
parts are disassembled in a way that will not affect
their performance or external appearance. Identify
parts so reassembly can be performed easily and
efficiently.

Inspection of Parts

• When removed, inspect each part for malfunction­ing, deformation, damage and other problems.

BESM010007

BESM010008

BESM010009

01

01–5

Chery Automobile Co., Ltd.

Arrangement of Parts

• All disassembled parts should be carefully arranged
for reassembly.

• Be sure to separate and identify the parts to be
replaced from those that will be reused.

Cleaning of Parts

• Carefully and thoroughly clean all parts to be
reused.

WARNING!

Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective
eye wear whenever using compressed air.

Component Reassembly

• Standard values, such as torques and certain
adjustments, must be strictly observed in the reas­sembly of all parts. If removed, replace these parts
with new ones:

− Oil seals

− Gaskets

− O-rings

− Lock washers

− Cotter pins

− Nylon nuts

PROPER SERVICE PRACTICES

BESM010010

BESM010011

BESM010012

01–6

Chery Automobile Co., Ltd.

Depending on location:

• Apply sealant and gaskets, or both, to specified
locations. When sealant is applied, install parts
before sealant hardens to prevent leaks.

• Apply oil to the moving components of parts.

• Apply specified oil or grease at the prescribed loca-

tions (such as oil seals) before reassembly.

Adjustments

• Use suitable gauges and testers when making
adjustments.

Rubber Parts and Rubber Tubing

• Prevent gasoline or oil from getting on rubber parts
or tubing.

PROPER SERVICE PRACTICES

BESM010013

BESM010014

BESM010015

01

01–7

Chery Automobile Co., Ltd.

Hose Clamps

• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.

Vise

• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.

Dynamometer

• When test-running a vehicle on a dynamometer:

− Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.

− Connect an exhaust gas ventilation unit.

WARNING!

Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing
it can make you unconscious and can eventually poison you.

− Cool the exhaust pipes with a fan.

− Keep the area around the vehicle uncluttered.

− Monitor the engine coolant temperature gauge.

PROPER SERVICE PRACTICES

BESM010016

BESM010017

01–8

Chery Automobile Co., Ltd.

VEHICLE INFORMATION

VEHICLE IDENTIFICATION NUMBER

(VIN)

01-10
VIN Location 01-10
VIN Identification Codes 01-11

INTERNATIONAL SYMBOLS

01-13

International Symbols 01-13

FASTENER USAGE

01-14

Fastener Usage 01-14

01

01–9

Chery Automobile Co., Ltd.

VEHICLE IDENTIFICATION NUMBER (VIN)

VIN Location

The VIN is printed on a plastic tag attached to the top right corner of the upper instrument panel. The VIN is also
found on the vehicle certification (VC) label.

Vehicle Identification Number (VIN) Tag Location

PZSM010002

01–10

Chery Automobile Co., Ltd.

VIN Identification Codes

The vehicle identification number (VIN) is a 17-digit combination of letters and numbers.

VIN DIGIT DESIGNATION DEFINITION

1 World Manufacture Identifier

2 Brand Of The Vehicle

3 Vehicle Chassis Type

4 Transmission Type

5 Engine Type

6 Restraint System

7 Check Digit

8 Model Year

9 Assembly Plant

10 Production Sequence Number

• Digits #1, #2, #3 The first 3 vehicle identification number (VIN) positions are the world manufacturer identifier:

− 9LVV9 represents Chery Automobile Co., Ltd.

• Digit #4 The fourth digit of the VIN code represents the brand of the vehicle:

− The brand 9Chery9 is represented by the letter 9D9.

• Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle:

− 9A9 represents three compartments, five-door, and 4X2.

− 9B9 represents two compartments, five-door, and 4X2.

− 9C9 represents three compartments, four-door, two-lid, and 4X2.

− 9D9 represents two compartments, five-door, and 4X4.

• Digit #6 The sixth digit of the VIN code represents the type of transmission:

− 919 represents manual transmission.

− 929 represents automatic transmission.

VEHICLE IDENTIFICATION NUMBER (VIN)

PZSM020054

01

01–11

Chery Automobile Co., Ltd.

• Digit #7 The seventh digit of the VIN code represents the type of engine:

− 919 represents electronically controlled gasoline engines 1.5L - 2.0L (excluding 2.0L) series.

− 929 represents engines smaller than 1.5L (excluding 1.5L).

− 949 represents 2.0L - 2.5L engines (excluding 2.5L).

• Digit #8 The eighth digit of the VIN code represents the Restraint System:

− 9A9 represents manual safety belts.

− 9B9 represents manual safety belts plus air bags in the front row.

• Digit #9 The ninth digit of the VIN code is the check digit:

− It is to check accuracy of VIN record, and is made out through computation after confirming the other six­teen digits of the VIN.

• Digit #10 The tenth VIN position represents the model year code:

− 959 represents the year 2005.

• Digit #11 The eleventh VIN position represents the assembly plant code:

− 9D9 represents the 9Chery Automobile Co., Ltd.9

• Digits #12, #13, #14, #15, #16, #17 The last six VIN positions represent the production sequence number.

− This represents the actual production number of the vehicle.

VEHICLE IDENTIFICATION NUMBER (VIN)

01–12

Chery Automobile Co., Ltd.

INTERNATIONAL SYMBOLS

International Symbols

The graphic symbols illustrated in the following International Control and Display Symbols chart are used to identify var­ious instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

International Control and Display Symbols

1 - High Beam

2 - Fog Lamps

3 - Headlamp, Parking Lamps, Panel Lamps

4 - Turn Signals

5 - Hazard Warning

6 - Windshield Washer

7 - Windshield Wiper

8 - Windshield Wiper and Washer

9 - Windshield Defroster

10 - Blower Motor Fan

11 - Rear Window Defroster

12 - Rear Window Wiper

13 - Rear Window Washer

14 - Fuel

15 - Engine Coolant Temperature

16 - Battery Charging Condition

17 - Engine Oil

18 - Seat Belt

19 - Brake Failure

20 - Parking Brake

21 - Hood

22 - Trunk

23 - Horn

24 - Cigarette Lighter

BESM010003

01

01–13

Chery Automobile Co., Ltd.

FASTENER USAGE

Fastener Usage

WARNING!

Use of an incorrect fastener may result in component damage. Failure to follow these instructions may result in
personal injury or death.

Fasteners and torque specification references in this Service Manual are identified in metric format.

During any maintenance or repair procedure, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly.
If the fastener is not salvageable, a fastener of equivalent specification must be used.

01–14

Chery Automobile Co., Ltd.

ELECTRICAL CIRCUIT DIAGNOSIS INFORMATION

DIAGNOSING ELECTRICAL

FAILURES

01-16
Performing Efficient Electrical Circuit
Diagnosis and Troubleshooting 01-16

Electrical Circuit Simulation Tests 01-16
Precautions For Handling Control Modules
and Electrical Components 01-18
How To Check Electrical Connectors 01-19

01

01–15

Chery Automobile Co., Ltd.

DIAGNOSING ELECTRICAL FAILURES

Performing Efficient Electrical Circuit Diagnosis and Troubleshooting

STEP DESCRIPTION

Step 1

Obtain detailed information about the conditions and the environment when the electrical
incident occurred.

Step 2

Operate the affected system, road test the vehicle if necessary.
Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Electrical Failure Simulation Tests”.

Step 3

Gather the proper diagnostic material including the following:

• Electrical Power Supply Routing Diagram

• System Operation Descriptions

• Applicable Service Manual Sections

• Check for any Service Bulletins

Identify where to begin diagnosis based upon your knowledge of the system operation
and the customer comments.

Step 4

Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Electrical
Power Supply Routing Diagram and Harness Layouts.

Step 5 Repair the circuit or replace the component as necessary.

Step 6

Operate the system in all modes. Verify the system functions properly under all conditions.
Confirm you have not inadvertently created an additional new incident during your
diagnosis or repair steps.

Electrical Circuit Simulation Tests

Often the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions
present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following illustrates
tests to simulate the conditions/environment under which the owner experiences an electrical incident.

The tests are broken into the seven following topics:

• Vehicle Vibration Test

• Heat Sensitive Test

• Freezing Test

• Water Intrusion Test

• Electrical Load Test

• Cold or Hot Start Up Test

• Voltage Drop Test

NOTE :

Always get a thorough description of the incident from the customer. It is important for simulating the conditions of
the problem.

Vehicle Vibration Test

The problem may occur or become worse while driving on a rough road or when the engine is vibrating (idle with A/C
on). In such a case, check for a vibration related condition. Refer to the following vehicle areas:

Connectors & Harness

• Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This
test may indicate a loose or poor electrical connection.

NOTE :

Connectors can be exposed to moisture. It is possible for a thin film of corrosion to form on the connector terminals.
A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, per­haps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related
connectors in the system.

01–16

Chery Automobile Co., Ltd.

Sensors & Relays

• Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a
loose or poorly mounted sensor or relay.

Engine Compartment

• There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things
to check for are:

− Connectors not fully seated.

− Wiring harness not long enough and is being stressed due to engine vibrations or rocking.

− Wires laying across brackets or moving components.

− Loose, dirty or corroded ground wires.

− Wires routed too close to hot components.

• To inspect components under the hood, start by verifying the integrity of the ground connections (See Ground
Inspection described later). First, verify that the system is properly grounded. Then check for any loose connec­tions by gently shaking the wiring or components as previously explained. Using the electrical schematics,
inspect the wiring for continuity.

Behind The Instrument Panel

• An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle
vibration can aggravate a harness which is routed along a bracket or near a mounting screw.

• An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.

Heat Sensitivity Test

The customer’s concern may occur during hot weather or after the vehicle has sat for a short time. In such cases you
will want to check for a heat sensitive condition.

To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent.

CAUTION:
Do not heat components above 60°C (140°F).

If the incident occurs while heat testing the component, replace or properly insulate the component as needed.

Freezing Test

The customer may indicate the incident goes away after the vehicle warms up (winter time). The cause could be
related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this:

• The first method is to arrange for the owner to leave the vehicle overnight. Make sure it will get cold enough to
duplicate the complaint. Leave the vehicle parked outside overnight. In the morning, do a quick and thorough
diagnosis of those electrical components which could be affected.

• The second method is to put the suspect component into a freezer long enough for any water to freeze. Rein­stall the part on the vehicle and check for a reoccurrence of the incident. If it occurs, repair or replace the
component as needed.

Water Intrusion Test

The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be
caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car
wash.

Electrical Load Test

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window
defogger, radio, fog lamps) turned on.

Cold or Hot Starting Test

On some occasions an electrical incident may occur only when the vehicle is started cold, or it may occur when the
vehicle is restarted hot shortly after being turned off. In these cases you may have to keep the vehicle overnight to
make a proper diagnosis.

DIAGNOSING ELECTRICAL FAILURES

01

01–17

Chery Automobile Co., Ltd.

Voltage Drop Test

Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in
a circuit is caused by a resistance in the circuit during operation.

• Check the circuit using a Digital Multimeter (DMM).

• When measuring resistance with a DMM, remember that contact by a single strand of wire will give a reading

of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able
to carry the current. The single strand will have a high resistance to the current. This will be indicated as a
slight voltage drop.

• Unwanted resistance can be caused by the following:

− Undersized wiring (single strand example)

− Corrosion on switch contacts

− Loose wire connections or splices

Precautions For Handling Control Modules and Electrical Components

• Never reverse polarity of battery terminals.

• Only install components specified for the vehicle.

• Before replacing the control module, check the input and output and functions of the components.

• When disconnecting components:

− Do not apply excessive force when disconnecting a connector.

− If a connector is installed by tightening bolts, loosen mounting bolt, then remove it by hand.

• When connecting components:

− Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it.

− When installing a connector by tightening bolts, tighten the mounting bolt until the painted area of the con­nector becomes even with the surface.

• Do not apply excessive shock to the control module by dropping or hitting it.

• Be careful to prevent condensation in the control module due to rapid temperature changes and do not let

water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.

• Be careful not to let oil get on the control module connector.

• Avoid cleaning the control module with volatile oil.

• When using a DMM, be careful not to let the test probes touch each other causing a short circuit. Prevent the

power transistor in the control module from being
shorted to damaging battery voltage.

• When checking input and output signals of the con­trol module, use the specified test adapter (if
applicable).

DIAGNOSING ELECTRICAL FAILURES

LTSMD030028

01–18

Chery Automobile Co., Ltd.

How To Check Electrical Connectors

Many electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking com­ponent or relay to cause a problem. Before condemning a component or wiring assembly always check the electrical
connectors for good continuity.

How To Probe Connectors

• Connector damage and an intermittent connection can result from improperly probing the connector during cir­cuit checks.

• The probe of a DMM may not correctly fit the connector cavity. To correctly probe the connector, follow the pro­cedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

Probing From Harness Side

• If the connector has a rear cover connector, remove the rear cover before probing the terminal.

• Do not probe waterproof connectors from the harness side. Damage to the seal between the wire and connec-

tor may result.

Probing From Terminal Side

• Female Terminal:

− Do not insert any object into the female connector that is bigger than the male terminal.

• Male Terminal:

− Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

How To Check Proper Contact Spring Tension Of Terminal

• An enlarged contact spring of a terminal may create intermittent signals in the circuit.

• If an intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact

spring of female terminal.

− Use a male terminal which matches the female terminal.

− Disconnect the suspected faulty connector and hold it terminal side up.

− While holding the wire of the male terminal, attempt to insert the male terminal into the female terminal.

− While moving the connector, check whether the male terminal can be easily inserted or not.

NOTE :

If the male terminal can be easily inserted into the female terminal, replace the female terminal.

DIAGNOSING ELECTRICAL FAILURES

01

01–19

Chery Automobile Co., Ltd.

ELECTRICAL INFORMATION

HOW TO READ ELECTRICAL

SCHEMATICS

01-21
Connector Symbols 01-21
Option Splices 01-22
Electrical Schematic - Example 01-23

HOW TO LOCATE ELECTRICAL

SCHEMATICS IN THE SERVICE
MANUAL

01-25

Electrical Schematic Index 01-25

01–20

Chery Automobile Co., Ltd.

HOW TO READ ELECTRICAL SCHEMATICS

Connector Symbols

• Connector symbols shown from the terminal side
are enclosed by a single line and followed by the
direction mark.

• Connector symbols shown from the harness side
are enclosed by a double line and followed by the
direction mark.

• Most of the connector symbols in the electrical
schematics are shown from the terminal side.

• In electrical schematics, female terminal end views
are shown at the bottom of the page for all compo­nents that are shown on the schematic page.

BESMW010003T

PZSMW010009T

01

01–21

Chery Automobile Co., Ltd.

Option Splices

• Option splices are shown with solid squared boxes with identification numbers inside.

HOW TO READ ELECTRICAL SCHEMATICS

BESMW010002T

01–22

Chery Automobile Co., Ltd.

Electrical Schematic - Example

HOW TO READ ELECTRICAL SCHEMATICS

BESMW010001T

01

01–23

Chery Automobile Co., Ltd.

Below is a list of the symbols and their definitions that are used in the electrical schematics.

NUMBER ITEM DESCRIPTION

1 Power source

This represents the condition when the system receives battery
positive voltage.

2 Fuse The single line represents that this is a fuse.

3 Current rating This represents the current rating of the fuse.

4 Fuse location

This represents the location of the fuse in the Power Fuse Box or
Front Fuse and Relay Box.

5 Connectors

This represents connector E-101 is female and connector C-101 is
male.

6 Terminal number This represents the terminal number of a connector.

7 Component name This represents the name of a component.

8 Connector number

This represents the connector number.
The letter represents which harness the connector is located in.

9 Splice

The shaded circle represents that the splice is always on the
vehicle.

10 Optional splice

The open circle represents that the splice is optional depending on
vehicle application.

11 Option abbreviation

This represents that the circuit is optional depending on vehicle
application.

12 Ground (GND)

This represents the ground connection. (See Ground Distribution in
Section 16 Wiring).
Ground connector number has no view face.

13 Page crossing

This arrow represents that the circuit continues to an adjacent page.
The 9A9 corresponds with the 9A9 on the adjoining page of the
electrical schematic.

14 Data link

This represents that the system branches to another system
identified by cell data code.

15 Option description

This represents a description of the option abbreviation used on the
page.

16 Connector views

This represents the connector information.
This component side is described by the connector symbols.

17 Connector color

This shows a code for the color of the connector:
B = Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
BR = Brown
O = Orange
GR = Gray

18 Shielded line The line enclosed by broken line circle represents shielded wire.

19 Light-emitting diodes As an illumination tool, in the circuit and instrument cluster.

HOW TO READ ELECTRICAL SCHEMATICS

01–24

Chery Automobile Co., Ltd.

HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE

SERVICE MANUAL

Electrical Schematic Index

The following table shows where to locate a specific electrical schematic for a vehicle component or system. The
electrical schematics are found throughout the service manual and are easily identified by their components or vehi­cle systems.

NOTE :

Some service manual chapters DO NOT contain electrical schematics, and will be identified as None in the Com­ponent/Vehicle System column.

SERVICE MANUAL CHAPTER COMPONENT / VEHICLE SYSTEM

01 - General Information • None

02 - Engine • None

03 - Electronic Engine Controls

• Engine Control Module (ECM)

• Engine Coolant Temperature Sensor

• Knock Sensor

• Upstream Oxygen Sensor

• Downstream Oxygen Sensor

• Crankshaft Position Sensor

• Camshaft Position Sensor

• Ignition Coil

• Canister Control Valve

• Front Fuse and Relay Box

• A/C Compressor

• Fuel Level Sensor and Fuel Pump

• Fuel Injectors

• A/C Pressure Switch

• Brake Switch

• Vehicle Speed Sensor

• Throttle Pedal Position Sensor

• Power Steering Switch

• Clutch Pedal Switch

• Electronic Throttle Control Actuator

• Manifold Absolute Pressure Sensor

• Vehicle Speed Sensor

04 - Fuel Delivery

• Fuel Injectors

• Fuel Level Sensor and Fuel Pump

05 - Starting & Charging

• Starter Motor

• Ignition Switch

• Clutch Pedal Switch

• Generator

06 - Cooling System • Cooling Fan

01

01–25

Chery Automobile Co., Ltd.

SERVICE MANUAL CHAPTER COMPONENT / VEHICLE SYSTEM

07 - Exhaust • None

08 - Transmission

• Backup Lamp Switch

• Clutch Solenoid Valve

• Gear Engagement Solenoid Valve

• Gearshift Selection Solenoid Valve

• Engagement Position Sensor

• Gearshift Selection Sensor

• Hydraulic Pressure Sensor

• Clutch Position Sensor

09 - Axle • None

10 - Suspension • None

11 - Steering • Power Steering Switch

12 - Brakes

• Antilock Brake System (ABS) Module

• Wheel Speed Sensors

• Brake Switch

• Parking Brake Switch

• Brake Fluid Level Switch

• Brake Pad Wear Sensor

13 - Heating & Air Conditioning

• Manual Temperature Control System

• Blower Motor

• A/C Compressor

• A/C Pressure Switch

14 - Restraints

• Restraints Control Module

• Seatbelt Buckle Switch

• Driver Airbag

• Passenger Airbag

HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL

01–26

Chery Automobile Co., Ltd.

SERVICE MANUAL CHAPTER COMPONENT / VEHICLE SYSTEM

15 - Body & Accessories

• Windshield Wiper Motor

• Windshield Washer Motor

• Rear Window Defroster

• Power Door Locks

• Power Windows

• Power Mirrors

• Sonar Module

• Radio

• Interior Lights

• Exterior Lights

• Siren

• Body Control Module (BCM)

• Trunk Opening Switch

• Trunk Release Solenoid

• Instrument Cluster

• Key Switch

• Power Outlet

• Data Link Connector

• Horn

• Immobilizer Control Module

16 - Wiring

• Power Distribution

• Front Fuse and Relay Box

• Power Fuse Box

• Ignition Switch

• Ground Distribution

Abbreviation List

TERM ABBREVIATION

Antilock Brake System ABS

Accelerator Sensor AES

Accelerator Pedal Position Sensor APPS

Automated Manual Transaxle AMT

Body Control Module BCM

Brake Pressure Sensor BPS

Camshaft Position Sensor CMP Sensor

Clutch Pedal Position Switch CPP Switch

Crankshaft Position Sensor CKP Sensor

Data Link Connector DLC

Diagnostic Trouble Code DTC

Engine Control Module ECM

Engine Coolant Temperature Sensor ECT Sensor

Engine Speed RPM

Evaporative Emission EVAP

Evaporative Emission Canister EVAP Canister

Evaporative Emission System EVAP System

Front Left Wheel Speed Sensor FLS

Front Right Wheel Speed Sensor FRS

HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL

01

01–27

Chery Automobile Co., Ltd.

TERM ABBREVIATION

Rear Left Wheel Speed Sensor RCS

Rear Right Wheel Speed Sensor RRS

Ground GND

Heated Oxygen Sensor O2S

Idle Air Control IAC

Ignition IGN

Ignition Control IC

Injector INJ

Input Shaft Speed Sensor ISS Sensor

Immobilizer Control Module ICM

Knock Sensor KS

Manifold Absolute Pressure Sensor MAP Sensor

Malfunction Indicator Lamp MIL

Oil Pressure Switch OPS

Output Shaft Speed Sensor OSS Sensor

Positive Crankcase Ventilation Valve PCV Valve

Power Supply PWR

SRS Airbag Control System SRC

Throttle Position Sensor TPS

Vehicle Identification Number VIN

Vehicle Speed Sensor VSS

HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL

01–28

Chery Automobile Co., Ltd.

ENGINE

02

CONTENTS

page

1.3L Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1

1.3L ENGINE MECHANICAL

GENERAL INFORMATION

02-3
Description 02-3
Operation 02-3
Specifications 02-3
Special Tools 02-7
Lubrication System 02-10

DIAGNOSIS & TESTING

02-13
Engine Performance Diagnostics 02-13
Engine Mechanical Diagnostics 02-14
Cylinder Compression Pressure Test 02-15
Cylinder Head Gasket Test 02-15

ON-VEHICLE SERVICE

02-16

Accessory Drive Belt 02-16

Removal & Installation 02-16

Air Cleaner Element 02-18

Removal & Installation 02-18

Air Cleaner Housing 02-18

Removal & Installation 02-18

Cylinder Head Cover 02-19

Removal & Installation 02-19

Camshaft 02-22

Removal & Installation 02-22

Cylinder Head 02-26

Removal & Installation 02-26

Front Crankshaft Oil Seal 02-28

Removal & Installation 02-28

Rear Crankshaft Oil Seal 02-29

Removal & Installation 02-29

Engine Mounts 02-31

Removal & Installation - Left Mount 02-31
Removal & Installation - Right Mount 02-31
Removal & Installation - Front Mount 02-32
Removal & Installation - Rear Mount 02-32

Engine Assembly 02-33

Removal & Installation 02-33

Engine Timing Belt 02-40

Removal & Installation 02-40

Exhaust Manifold 02-44

Removal & Installation 02-44

Intake Manifold 02-46

Removal & Installation 02-46

Oil Filter 02-49

Removal & Installation 02-49

Oil Pan 02-50

Removal & Installation 02-50

Oil Pump 02-51

Removal & Installation 02-51

Oil Strainer 02-52

Removal & Installation 02-52

ENGINE UNIT REPAIR

02-53

Engine Block 02-53

Specifications 02-53
Disassembly 02-53
Inspection 02-55
Assembly 02-55

Pistons 02-56

Specifications 02-56
Disassembly 02-57
Inspection 02-58
Assembly 02-60

Connecting Rods 02-61

Specifications 02-61
Disassembly 02-61
Inspection 02-62
Assembly 02-62

Crankshaft 02-63

Specifications 02-63
Disassembly 02-63
Inspection 02-64
Assembly 02-65

02

02–1

Chery Automobile Co., Ltd.

CYLINDER HEAD UNIT REPAIR

02-66

Cylinder Head 02-66

Specifications 02-66
Disassembly 02-66
Inspection 02-68
Assembly 02-68

Camshaft 02-69

Specifications 02-69
Disassembly 02-70
Inspection 02-70
Assembly 02-72

Valve & Valve Guides 02-73

Specifications 02-73
Disassembly 02-73
Inspection 02-74
Assembly 02-75

Valve Springs 02-76

Specifications 02-76
Disassembly 02-77
Inspection 02-78
Assembly 02-78

02–2

Chery Automobile Co., Ltd.

GENERAL INFORMATION

Description

The 1.3L in-line four cylinder engine has the following features:

• Double overhead camshafts

• Four valves per cylinder

• Aluminum cylinder head

• Cast iron cylinder block

Operation

The 1.3L engine utilizes 4 valve-per-cylinder and a double overhead camshaft design. The engine uses an individual
coil ignition system. The cylinder block is made of cast iron and the bearing caps are integrated into the lower cyl­inder block assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block. The camshafts are
mounted in the cylinder head and act against valve tappets to open and close the valves. The camshafts are driven
off the front of the cylinder head by one timing belt. The belt is driven by a sprocket that is located on the crankshaft.
The piston assembly is an aluminum piston with a cast iron connecting rod.

The aluminum cylinder head contains double overhead camshafts with four valves per cylinder. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Specifications

1.3L Engine Specifications

DESCRIPTION SPECIFICATION

Type In-Line OHV, DOHC

Number of Cylinders 4

Compression Ratio 10.0:1

Compression Pressure 10.0 - 13.5 bar

Max. Compression Pressure Variation Between
Cylinders

30%

Stroke 77.5 mm

Cylinder Volume 1.297 L

Bore 73 mm

Fuel Designation (Not less than) #93

Engine Oil Quantity 3.5 L

Fuel Supply Mode Multi-Point Electronic Controlled Gasoline Injection

Engine Oil Designation SAE 10W-40 (Grade SL or above)

Displacement 1297 cc

Firing Order 1-3-4-2

02

02–3

Chery Automobile Co., Ltd.

Mechanical Specifications

DESCRIPTION ITEM STANDARD LIMIT

Engine Oil Pressure

Lower Idle Speed

(800 ± 50 RPM)

1.2 - 1.5 bar -

High Idle Speed

(2000 RPM)

3.2 - 3.5 bar -

High Speed (4000 RPM) 3.7 ± 0.5 bar -

Engine Block Clearance

Surface Distortion - 0.15 mm

Inner Diameter 73.005 ± 0.005 mm -

Out-Of-Round - Less than 0.008 mm

Taper - Less than 0.01 mm

Piston Ring Groove
Clearance

First Ring 0.035 - 0.08 mm -

Second Ring 0.025 - 0.07 mm -

Piston To Piston Pin
Clearance

- 0.013 - 0.018 mm -

Piston Diameter - 72.965 ± 0.009 mm -

Connecting Rod Radial
Clearance

- 0.023 - 0.058 mm -

Connecting Rod Axial
Clearance

- 0.15 - 0.4 mm -

Diameter Of Crankshaft
Main Journals

- 46.01 mm -

Diameter Of Crankshaft
Rod Journals

- 44.485 - 44.495 mm -

Out-Of-Round Maximum
Of Crankshaft Main
Journals

- - Less than 0.008 mm

Axial Clearance Of
Crankshaft

- 0.02 - 0.30 mm -

Radial Clearance Of
Crankshaft

- 0.0035 - 0.034 mm -

Coaxality Crankshaft Main
Journal

- - Less than 0.005 mm

Thrust Washer Thickness - 2.4 - 2.405 mm -

Oil Clearance Of
Crankshaft Rod And Main
Journals

- 0.02 mm 0.06 mm

Cylinder Head Flatness - 0.05 - 0.10 mm -

Intake Valve Deflection - - Less than 0.02 mm

Exhaust Valve Deflection - - Less than 0.04 mm

Spring Height - 49.0 mm -

Spring Height At 620
Newtons Of Pressure

- 32.0 mm -

Intake Cam Lobe Height - 37.09 mm -

Exhaust Cam Lobe Height - 37.05 mm -

Camshaft Journal #1 Outer
Diameter

- 31.934 - 31.95 mm -

Camshaft Journal #2, #3,
#4, #5, Outer Diameter

- 23.947 - 23.96 mm -

GENERAL INFORMATION

02–4

Chery Automobile Co., Ltd.

DESCRIPTION ITEM STANDARD LIMIT

Camshaft Cam Bearing #1
Inner Diameter

- 32 - 32.025 mm -

Camshaft Cam Bearing
#2, #3, #4, #5, Inner
Diameter

- 24 - 24.021 mm -

Camshaft Journal #1
Clearance

- 0.05 - 0.090 mm -

Camshaft Journal #2, #3,
#4, #5 Clearance

- 0.04 - 0.074 mm -

Intake Camshaft Axial
Clearance

- 0.15 - 0.20 mm -

Exhaust Camshaft Axial
Clearance

- 0.15 - 0.20 mm -

Intake Valve Guide
Clearance

- 0.012 - 0.043 mm -

Exhaust Valve Guide
Clearance

- 0.032 - 0.063 mm -

Valve Outer Diameter

Intake Valve 5.98 ± 0.008 mm -

Exhaust Valve 5.96 ± 0.008 mm -

Valve Guide Inner
Diameter

Intake Valve 5.4 ± 0.1 mm -

Exhaust Valve 5.4 ± 0.1 mm -

Fringe Thickness On Top
Of Valve

Intake Valve 0.3 ± 0.15 mm -

Exhaust Valve 0.3 ± 0.15 mm -

Valve Tilt Angle

Intake Valve 65° -

Exhaust Valve 68° -

Valve Height

Intake Valve 107.998 mm -

Exhaust Valve 106.318 mm -

Torque Specifications

CAUTION:
When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.

DESCRIPTION TORQUE (N·m)

A/C Compressor Line Bolt 20 ± 5

Camshaft Bearing Cap Bolts 9.5 ± 1.5

Clutch Pressure Plate Bolts 25 ± 5

Connecting Rod Cap Bolts

1st Step: Tighten the bolt to 25 ± 3 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°

Crankshaft Holder 28

Crankshaft Main Bearing Cap Bolts

1st Step: Tighten the bolt to 45 ± 5 N·m

2nd Step: Tighten the bolt an additional 180 ± 10°

Crankshaft Timing Belt Pulley Bolt

1st Step: Tighten the bolt to 130 ± 10 N·m

2nd Step: Tighten the bolt an additional 65 ± 5°

Crankshaft Vibration Damper Bolts

25 ± 5

2nd Step: Tighten the bolt an additional 30 ± 5°

Camshaft Timing Belt Pulley Bolt 120 ± 5

Cylinder Head Cover Bolts 10 ± 2

GENERAL INFORMATION

02

02–5

Chery Automobile Co., Ltd.

DESCRIPTION TORQUE (N·m)

Cylinder Head Bolts

1st Step: Tighten the bolt to 50 ± 5 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°

3rd Step: Tighten the bolt an additional 90 ± 5°

Dipstick Bracket Bolts 10 ± 2

Engine Left Mount Bolt 65 ± 5

Engine Right Mount Bolt 65 ± 5

Engine Front Mount Bolt 80 ± 5

Engine Rear Mount Bolt 60 ± 5

Engine To Transaxle Bolts 70 ± 5

Exhaust Manifold Nuts 20 ± 5

Exhaust Manifold To Catalytic Converter Bolts 60 ± 5

Exhaust Manifold Heat Shield Bolts 10 ± 5

Exhaust Camshaft Timing Belt Pulley Bolt 120 ± 5

Fuel Rail Bracket Bolts 10 ± 3

Flywheel Bolt

1st Step: Tighten the bolt to 15 ± 5 N·m

2nd Step: Tighten the bolt an additional 30 ± 5°

Idler Pulley Bolt 40 ± 5

Intake Camshaft Timing Belt Pulley Bolt 120 ± 5

Intake Manifold Bolts 8 ± 3

Intake Manifold Nuts 8 ± 3

Intake Manifold Bracket Bolts 20 ± 5

Lower Idler Pulley Bolt 40 ± 5

Lower Cylinder Block Bolts 25 ± 5

Oil Filter 25 ± 3

Oil Pan Bolts 15 ± 5

Oil Drain Plug 25 ± 3

Oil Strainer Bolts 18

Oil Pump Bolts

8 ± 3

(Apply with Loctite 5910 Thread-Locker)

Rear Timing Cover Bolts 8 ± 3

Timing Belt Upper Cover Bolts 8 ± 3

Timing Belt Lower Cover Bolts 8 ± 3

Timing Belt Tensioner Assembly 27 ± 3

Timing Belt Tensioner Pulley Bolt 45 ± 5

Shift Cable Bracket Bolts 25 ± 5

Throttle Body Bolts 8 ± 3

Upper Idler Pulley Bolt 45 ± 5

GENERAL INFORMATION

02–6

Chery Automobile Co., Ltd.

Special Tools

Right Engine Mount Bolt Remover

CH-20001

Camshaft Seal Installer

CH-20002

Crankshaft Holder

CH-20003

Valve Spring Compressor Adaptor

CH-20004

Rear Crankshaft Oil Seal Installer

CH-20005

GENERAL INFORMATION

02

02–7

Chery Automobile Co., Ltd.

Rear Crankshaft Oil Seal Guide

CH-20006

Front Crankshaft Seal Installer

CH-20007

Front Crankshaft Seal Guide

CH-20008

Flywheel Fixture

CH-20009

Camshaft Holder

CH-20010

GENERAL INFORMATION

02–8

Chery Automobile Co., Ltd.

Valve Seal Installer

CH-20011

Valve Stem Seal Installer Guide

CH-20012

Valve Seal Remover

CH-20013

Valve Keeper Installer

CH-20017

Valve Spring Compressor

CH-20018

GENERAL INFORMATION

02

02–9

Chery Automobile Co., Ltd.

Crankshaft Belt Pulley Fixture

CH-20019

Engine Hoist

Oil Filter Remover

CH-10003

Lubrication System

The engine lubrication system operates as follows:

• Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan.

• Oil is pumped through the oil filter on the cylinder block.

• Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head.

• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the con-

necting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is
slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and
piston ring assembly.

• The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the
engine block. The pump inner rotor is driven by the crankshaft.

Engine Oil Pressure Specifications

Idle Speed (950 ± 10 RPM) 2.7 Bar

GENERAL INFORMATION

02–10

Chery Automobile Co., Ltd.

Engine Lubrication System Exploded View

1 - Oil Dipstick

2 - Oil Dipstick Bolt

3 - Oil Dipstick Bracket

4 - Oil Dipstick Guide

5 - Crankshaft Rear Oil Seal

6 - O-Ring

7 - Oil Filter Bracket Gasket

8 - Oil Filter Bracket

9 - Pressure-relief Plunger

10 - Flange Bolt

11 - Flange Bolt

12 - Oil Filter Seat

13 - Oil Filter Connector

14 - Oil Filter

15 - Dowel Pin

16 - Oil Pan Bolt

17 - Oil Pan Bolt

18 - Oil Pan Bolt

19 - Oil Pan

20 - O-Ring

21 - O-Ring

22 - Oil Pump Strainer Bolt

23 - Oil Pump Strainer

24 - Baffle Plate

25 - O-Ring

26 - O-Ring

27 - Crankshaft Front Oil Seal

28 - Oil Pump Bolt

29 - Oil Pump Assembly

30 - Oil Pump Assembly Gasket

GENERAL INFORMATION

PZSM020035

02

02–11

Chery Automobile Co., Ltd.

Engine Oil Flow Diagram

1 – Oil Pump Strainer

2 – Baffle Plate

3 – Oil Pan

4 – Oil Pump

5 – Turbocharger Inlet Oil Passage (if equipped)

6 – To Cylinder Head

7 – Oil Return Passage

8 – To Front Bearing Cap

9 – To Middle Bearing Cap

10 – Oil Dipstick

11 – To Crankcase

12 – Crankcase Pipe

13 – Oil Filter Bracket

14 – Oil Pressure Switch

15 – Oil Filter

GENERAL INFORMATION

PZSM020036

02–12

Chery Automobile Co., Ltd.

DIAGNOSIS & TESTING

Engine Performance Diagnostics

CONDITION POSSIBLE CAUSE CORRECTION

Engine Does Not Start

1. Weak battery.

2. Corroded or loose battery
connections.

3. Faulty starter.

4. Faulty coil(s) or control unit.

5. Incorrect spark plug gap.

6. Contamination in fuel system.

7. Faulty fuel pump.

8. Incorrect timing.

1. Test battery. Charge or replace if
necessary.

2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.

3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)

4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)

5. Set gap.

6. Clean system and replace fuel
filter.

7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)

8. Check for a skipped timing belt.

Engine Stalls Or Idles Rough

1. Idle speed too low.

2. Incorrect fuel mixture.

3. Intake manifold leakage.

4. Faulty ignition coil(s).

1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)

2. (Refer to Appropriate Diagnostic
Information)

3. Inspect intake manifold, manifold
gasket, and vacuum hoses.

4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

Engine Loss Of Power

1. Dirty or incorrectly gapped spark
plugs.

2. Contamination in fuel system.

3. Faulty fuel pump.

4. Incorrect valve timing.

5. Leaking cylinder head gasket.

6. Low compression.

7. Burned, warped, excessive
clearance or pitted valves.

8. Plugged or restricted exhaust
system.

9. Faulty ignition coil(s).

10. Burned spark plugs.

1. Clean spark plugs and set gap.

2. Clean system and replace fuel
filter.

3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

4. Correct valve timing.

5. Replace cylinder head gasket.

6. Test compression of each
cylinder.

7. Replace valves.

8. Perform exhaust restriction test.
Install new parts.

9. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

10. Replace spark plugs.

Engine Miss On Acceleration

1. Dirty or incorrectly gapped spark
plugs.

2. Contamination in fuel system.

3. Burned, warped, or pitted valves.

4. Faulty ignition coil(s).

1. Clean spark plugs and set gap.

2. Clean fuel system and replace
fuel filter.

3. Replace valves.

4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

DIAGNOSIS & TESTING

02

02–13

Chery Automobile Co., Ltd.

CONDITION POSSIBLE CAUSE CORRECTION

Engine Miss At High Speed

1. Dirty or incorrect spark plug gap.

2. Faulty ignition coil(s).

3. Dirty fuel injector(s).

4. Contamination in fuel system.

1. Clean spark plugs and set gap.

2. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)

4. Clean system and replace fuel
filter.

Engine Mechanical Diagnostics

CONDITION POSSIBLE CAUSE CORRECTION

Valve Train Noise

1. High or low oil level in crankcase.

2. Thin or diluted oil.

3. Thick oil.

4. Low oil pressure.

5. Worn cam lobe.

6. Worn valve guides.

7. Excessive runout of valve seats
on valve faces.

1. Check and correct engine oil
level.

2. Change oil to correct viscosity.

3. Change engine oil and filter.

4. Check and correct engine oil
level.

5. Install new camshaft.

6. Replace cylinder head.

7. Grind valve seats and replace
valves.

Connecting Rod Noise

1. Insufficient oil supply.

2. Low oil pressure.

3. Thin or diluted oil.

4. Excessive bearing clearance.

5. Connecting rod journal out-of­round.

6. Connecting rod out-of-round.

7. Misaligned connecting rods.

8. Connecting rod nuts loose.

1. Check engine oil level.

2. Check engine oil level. Inspect oil
pump relief valve and spring.

3. Change oil to correct viscosity.

4. Measure bearings for correct
clearance. Repair if necessary.

5. Replace crankshaft or grind
surface.

6. Replace connecting rod.

7. Replace bent connecting rods.

8. Tighten the connecting rod nuts.

Main Bearing Noise

1. Insufficient oil supply.

2. Low oil pressure.

3. Thin or diluted oil.

4. Excessive bearing clearance.

5. Excessive end play.

6. Crankshaft journal out-of-round or
worn.

7. Loose flywheel or torque
converter.

1. Check engine oil level.

2. Check engine oil level. Inspect oil
pump.

3. Change oil to correct viscosity.

4. Measure bearings for correct
clearance. Repair if necessary.

5. Check thrust bearing for wear on
flanges.

6. Replace crankshaft or grind
journals.

7. Tighten to correct torque.

Oil Pressure Drop

1. Low oil level.

2. Faulty oil pressure sending unit.

3. Low oil pressure.

4. Clogged oil filter.

5. Thin or diluted oil.

6. Excessive bearing clearance.

1. Check engine oil level.

2. Install new sending unit.

3. Check sending unit and main
bearing oil clearance.

4. Install new oil filter.

5. Change oil to correct viscosity.

6. Measure bearings for correct
clearance.

DIAGNOSIS & TESTING

02–14

Chery Automobile Co., Ltd.

CONDITION POSSIBLE CAUSE CORRECTION

Oil Leaks

1. Misaligned or deteriorated
gaskets.

2. Loose fastener, broken or porous
metal part.

3. Misaligned or deteriorated cup or
threaded plug.

1. Replace gasket.

2. Tighten, repair or replace the part.

3. Replace if necessary.

Oil Consumption Or Spark Plugs
Fouled

1. PCV system malfunction.

2. Worn, scuffed or broken rings.

3. Carbon in oil ring slots.

4. Rings fitted too tightly in grooves.

5. Worn valve guide(s).

6. Valve stem seal(s) worn or
damaged.

1. Check system and repair if
necessary.

2. Hone cylinder bores. Install new
rings.

3. Install new rings.

4. Remove rings and check grooves.
If groove is not proper width, replace
piston.

5. Replace cylinder head.

6. Replace seal(s).

Cylinder Compression Pressure Test

• The result of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

• Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise

the indicated compression pressures may not be valid for diagnostic purposes.

− Check engine oil level and add oil if necessary.

− Disconnect the spark plug wires.

− Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for abnormal
firing indicators fouled, hot, oily, etc.).

− Record cylinder number of each spark plug for future reference.

− Disconnect fuel injector electrical connectors.

− Be sure throttle blade is fully open during the compression check.

− Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.

− Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.

− Compression should not be less than 900 kPa and not vary more than 30 percent from cylinder to cylinder.

− If one or more cylinders have abnormally low compression pressures, repeat the compression test.

− If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could
indicate the existence of a problem with the cylinder in question.

NOTE :

The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine
should not be disassembled to determine the cause of low compression unless some malfunction is present.

Cylinder Head Gasket Test

• A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.

• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:

− Loss of engine power

− Engine misfiring

− Poor fuel economy

• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:

− Engine overheating

− Loss of coolant

− Excessive steam (white smoke) emitting from exhaust

− Coolant foaming

DIAGNOSIS & TESTING

02

02–15

Chery Automobile Co., Ltd.

ON-VEHICLE SERVICE

Accessory Drive Belt

Removal & Installation

WARNING!

Inspect the drive belt only when the engine is stopped.

1. Loosen the power steering pump adjustment bolt
(1).

1 - A/C Compressor Belt

2 - Power Steering Pump

3 - A/C Compressor

4 - Crankshaft Pulley

5 - Generator Belt

6 - Generator

PZSM020029

PZSM020005

02–16

Chery Automobile Co., Ltd.

2. Loosen the two bolts (1) on the steering pump
bracket.

3. Remove the A/C compressor belt.

4. Loosen the generator adjustment bolt (1).

5. Remove the generator belt.

6. Installation is in the reverse order of removal.

Installation Notes:

• Use a deflection gauge and adjust the drive belt tension to 95 N·m with a limit deflection of 5 mm.

NOTE :

Measure the drive belt deflection in the middle of the drive belt.

ON-VEHICLE SERVICE

PZSM020050

PZSM020014

02

02–17

Chery Automobile Co., Ltd.

Air Cleaner Element

Removal & Installation

1. Remove the two air cleaner case side bolts (1) and
remove the upper air cleaner case.

2. Remove the air cleaner element (1).

3. Install a new air cleaner element.

4. Installation is in the reverse order of removal.

Air Cleaner Housing

Removal & Installation

1. Remove the two retaining bolts (1) on the air intake
pipe.
(Tighten: Air intake pipe bolts to 8 ± 3 N·m)

ON-VEHICLE SERVICE

PZSM020040

PZSM020038

PZSM020001

02–18

Chery Automobile Co., Ltd.

2. Remove the clamps (1) between the intake mani­fold and the air cleaner housing.

3. Remove the PCV return hose clamp (1) on the
intake manifold hose.

4. Remove the intake manifold hose.

5. Remove the two air cleaner housing retaining bolts
(1).
(Tighten: Air cleaner housing bolts to 10 ± 5 N·m)

6. Remove the air cleaner housing.

7. Installation is in the reverse order of removal.

Cylinder Head Cover

Removal & Installation

1. Disconnect the negative battery cable.

ON-VEHICLE SERVICE

PZSM020003

PZSM020046

PZSM020002

02

02–19

Chery Automobile Co., Ltd.

2. Remove the clamps (1) between the intake mani­fold and the air cleaner housing.

3. Remove the PCV return hose clamp (1) on the
intake manifold hose.

4. Remove the intake manifold hose.

5. Disconnect the manifold air pressure (MAP) sensor
electrical connector.

6. Remove the MAP sensor retaining bolt (1) and
remove the MAP sensor.

7. Remove the four spark plug wires (1) and set them
aside.

ON-VEHICLE SERVICE

PZSM020003

PZSM020046

PZSM030004

PZSM030016

02–20

Chery Automobile Co., Ltd.

8. Remove the PCV hose clamp (1) and remove the
PCV hose from the cylinder head cover.

9. Remove the fuel vapor return hose clamp (1) and
remove the fuel vapor return hose from the throttle
body.

10. Disconnect the Camshaft Position (CMP) sensor
electrical connector.

11. Remove the CMP sensor retaining bolt (1) and

remove the CMP sensor.

ON-VEHICLE SERVICE

PZSM030019

PZSM030018

PZSM030011

02

02–21

Chery Automobile Co., Ltd.

12. Remove the two intake manifold bracket retaining
bolts (1).

13. Remove the intake manifold (See Intake manifold Removal & Installation in Section 02 Engine).

14. Remove the twelve cylinder head cover bolts (1).
(Tighten: Cylinder head cover bolts to 10 ± 2 N·m)

15. Remove the cylinder head cover.

16. Installation is in the reverse order of removal.

Camshaft

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20002 - Camshaft Seal Installer

• CH-20010 - Camshaft Holder

1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).

2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).

3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).

ON-VEHICLE SERVICE

PZSM020051

PZSM020034

02–22

Chery Automobile Co., Ltd.

4. Remove the intake and exhaust camshaft timing
belt pulley bolts (1).
(Tighten: Camshaft timing belt pulley bolt to 120 ±
5 N·m)

5. Remove the six rear timing cover bolts.
(Tighten: Rear timing cover bolts to 10 ± 2 N·m)

ON-VEHICLE SERVICE

PZSM020041

BESM020034

02

02–23

Chery Automobile Co., Ltd.

6. Remove the sixteen camshaft bearing cap bolts.
(Tighten: Camshaft bearing cap bolts to 9.5 ± 1.5 N·m )

NOTE: Equally loosen camshaft bearing cap bolts
in several steps.

7. Remove the camshaft bearing caps and place
them in proper order.

NOTE: The camshaft bearing caps are marked for
identification.

8. Remove the camshafts and then remove the cam­shaft seals.

9. Installation is in the reverse order of removal.

Installation Notes:

• Identify and separate the intake camshaft and the exhaust camshaft (the intake camshaft is identified by the
gear on the end of the camshaft).

• Pay attention to the division mark of the camshaft shell cover.

• Use special tool CH-20010 (1), and install the cam-

shaft holder to hold the camshafts in place.

NOTE :

The camshaft holder will prevent the camshafts from
rotating in either direction.

ON-VEHICLE SERVICE

BESM020035

BESM020016

02–24

Chery Automobile Co., Ltd.

• Use special tool CH-20002 (1), to install the camshaft seal.

• Install the camshaft seal in the required location

and depth.

• Install the intake and exhaust camshaft bearing caps in the proper order.

• Slowly tighten bolts to the specified torque.

• Follow the torque sequence as shown.

ON-VEHICLE SERVICE

LTSM020215

BESM020036

02

02–25

Chery Automobile Co., Ltd.

Cylinder Head

Removal & Installation

NOTE :

Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, and camshafts.

1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).

2. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).

3. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine).

4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).

5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine).

6. Remove water pipe and thermostat assembly.

1 - Rocker Arms

2 - Hydraulic Tappets

3 - Valve Keepers

4 - Valve Spring Upper Retainers

5 - Valve Springs

6 - Valve Oil Seals

7 - Valve Spring Lower Retainers

8 - Valves

ON-VEHICLE SERVICE

LTSM020167

02–26

Chery Automobile Co., Ltd.

7. Remove the ten cylinder head bolts in the order
shown.

8. Remove cylinder head gasket.

9. Installation is in the reverse order of removal.

Installation Notes:

• Ensure the cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are
not damaged.

• The cylinder head bolts should not be reused. The new bolts should be examined before use. If the bolts are
stretched, the bolts should be replaced.

• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in the block.

• Before installing the bolts, the threads should be lightly coated with engine oil.

ON-VEHICLE SERVICE

BESM020065

02

02–27

Chery Automobile Co., Ltd.

• Install the ten cylinder head bolts in the order shown.

• Torque the cylinder head bolts in the following three

step sequence:

− 1st Step: Tighten the bolt to 50 ± 5 N·m

− 2nd Step: Tighten the bolt an additional
90 ± 5°

− 3rd Step: Tighten the bolt an additional
90 ± 5°

Front Crankshaft Oil Seal

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20007 - Front Crankshaft Seal Installer

• CH-20008 - Front Crankshaft Seal Guide

1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).

2. Remove the six crankshaft vibration damper bolts
(1).
(Tighten: Crankshaft vibration damper bolts to 25 ±
5 N·m and an additional 30 ± 5°)

3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).

ON-VEHICLE SERVICE

LTSM020236

PZSM020017

02–28

Chery Automobile Co., Ltd.

4. Remove the crankshaft timing belt pulley bolt (2)
from the crankshaft.
(Tighten: Crankshaft timing belt pulley bolt to 130 ±
10 N·m and an additional 65 ± 5°)

5. Remove the key-way from the crankshaft.

6. Use an appropriate tool and remove the front
crankshaft oil seal (1).

CAUTION:
Be careful not to damage the front cover seal
surface while removing the seal.

7. Installation is in the reverse order of removal.

Installation Notes:

• Use the front crankshaft seal installer CH-20007 (1), to install the new seal.

• Lubricate the new front seal with engine oil prior to

assembly.

Rear Crankshaft Oil Seal

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20005 - Rear Crankshaft Oil Seal Installer

• CH-20006 - Rear Crankshaft Oil Seal Guide

• CH-20043 - Flywheel Fixture

1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).

2. Using special tool CH-20043 (1), hold the flywheel.

ON-VEHICLE SERVICE

LTSM020199

LTSM020216

PZSM020026

02

02–29

Chery Automobile Co., Ltd.

3. Remove the six clutch pressure plate retaining
bolts (1).
(Tighten: Clutch pressure plate bolts to 25 ± 5 N·m)

4. Remove the eight flywheel bolts (1) and then
remove the flywheel.
(Tighten: Flywheel bolts to 15 ± 5 N·m and an
additional 30 ± 5°)

5. Remove the rear oil seal using a suitable tool.

6. Installation is in the reverse order of removal.

Installation Notes:

• When installing seal, lubricate seal guide with clean
engine oil.

• Position the seal over the rear crankshaft seal
guide.

• Use special tool CH-20005 (2) and CH-20006 (1),
to install the rear crankshaft oil seal.

• Ensure that the lip of the seal is facing toward the
crankcase during installation.

ON-VEHICLE SERVICE

PZSM080006

BESM020058

LTSM020217

02–30

Chery Automobile Co., Ltd.

Engine Mounts

Removal & Installation - Left Mount

NOTE :

The following special tools are required to perform the repair procedure:

• Engine Hoist

1. Disconnect the negative battery cable.

2. Remove the battery (See Battery Removal & Installation in Section 05 Starting & Charging).

3. Remove the air cleaner housing (See Air Cleaner Housing Removal & Installation in Section 02 Engine).

4. Remove the four battery tray retaining bolts (1).

5. Remove the three left transaxle mount bolts (2)
and the three left transaxle mount bracket bolts (1).
(Tighten: Engine left mount bolt to 65 ± 5 N·m)

6. Installation is in the reverse order of removal.

Removal & Installation - Right Mount

NOTE :

The following special tools are required to perform the repair procedure:

• Engine Hoist

1. Use the engine hoist to support the engine.

ON-VEHICLE SERVICE

PZSM020021

PZSM020031

02

02–31

Chery Automobile Co., Ltd.

2. Remove the two right engine mount bolts (1) and
the three right engine mount bracket bolts (2).
(Tighten: Engine right mount bolt to 65 ± 5 N·m)

3. Installation is in the reverse order of removal.

Removal & Installation - Front Mount

NOTE :

The following special tools are required to perform the repair procedure:

• Engine Hoist

1. Use the engine hoist to support the engine.

2. Remove the two front engine mount bolts (1) and
the four front engine mount bracket bolts (2).
(Tighten: Engine front mount bolt to 80 ± 5 N·m)

3. Installation is in the reverse order of removal.

Removal & Installation - Rear Mount

NOTE :

The following special tools are required to perform the repair procedure:

• Engine Hoist

1. Raise and support the vehicle.

2. Remove the rear engine mount retaining bolts (2)
and the three rear engine mount bracket bolts (1).
(Tighten: Engine rear mount bolt to 60 ± 5 N·m)

3. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

PZSM020006

PZSM020032

PZSM020011

02–32

Chery Automobile Co., Ltd.

Engine Assembly

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20001 - Right Engine Mount Bolt Remover

• Engine Hoist

NOTE :

The engine is removed with the transaxle as an assembly.

1. Remove the vehicle hood.

2. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).

3. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).

4. Evacuate the A/C system (See A/C System Evacuation and Recharge in Section 13 Heating and Air Condition­ing).

5. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).

WARNING!

Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.

6. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in
Section 06 Cooling).

7. Remove the negative battery cable from the engine.

8. Remove the two retaining bolts (1) on the air intake
pipe.
(Tighten: Air intake pipe bolts to 8 ± 3 N·m)

9. Remove the clamps (1) between the intake mani­fold and the air cleaner housing.

10. Remove the intake manifold hose.

ON-VEHICLE SERVICE

PZSM020001

PZSM020003

02

02–33

Chery Automobile Co., Ltd.

11. Remove the PCV return hose clamp (1) on the
intake manifold hose.

12. Remove the two air cleaner case retaining bolts (1)

and remove the air cleaner case assembly.

13. Disconnect and remove the following electrical connectors:

 Coolant temperature sensor
 Camshaft position sensor

Ignition coil
Four fuel injectors
Intake manifold air pressure sensor
Carbon canister solenoid valve
Crankshaft position sensor
Throttle body control
A/C compressor
Oil pressure sensor
Power steering pump pressure switch
Generator
Backup lamp switch
Vehicle speed sensor

14. Remove the pipe (1) from the canister control

valve.

ON-VEHICLE SERVICE

PZSM020046

PZSM020002

PZSM080057

02–34

Chery Automobile Co., Ltd.
















15. Disconnect the heater hoses (1) on the vehicle.

16. Remove the vacuum line (1) from the brake

booster.

17. Remove the dipstick.

18. Remove the transaxle shift cable (1).

19. Remove the shift cable clamp (1) from the shift

cable bracket.

ON-VEHICLE SERVICE

PZSM020004

PZSM020044

PZSM080002

VISM080026

02

02–35

Chery Automobile Co., Ltd.

20. Remove the three shift cable bracket retaining

bolts (1).
(Tighten: Shift cable bracket retaining bolts to
25 ± 5 N·m)

21. Remove the three exhaust manifold heat shield

bolts (1) and then remove heat shield.
(Tighten: Exhaust manifold heat shield bolts to
20 ± 5 N·m)

22. Disconnect the upstream and downstream oxygen sensor connectors.

23. Remove the three catalytic converter to exhaust

manifold bolts (1).
(Tighten: Catalytic converter to exhaust manifold
bolts to 60 ± 5 N·m)

24. Remove the front axle shaft (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).

25. Drain the steering oil.

ON-VEHICLE SERVICE

VISM080025

PZSM020024

PZSM020008

02–36

Chery Automobile Co., Ltd.

26. Remove the power steering pump pressure pipe

(1) and return hose clamp (2).

27. Remove the A/C compressor line bolt (1) from the

A/C compressor.
(Tighten: A/C compressor line bolts to 20 ± 5 N·m)

NOTE: After removing the A/C lines, plug the A/C
lines to prevent any debris from entering the A/C
system.

28. Raise and support the vehicle.

29. Drain the engine oil.

30. Remove the exhaust pipe assembly (See Exhaust Pipe Assembly Removal & Installation in Section 07 Exhaust).

31. Remove the suction line retaining bolts on the front sub-frame.

ON-VEHICLE SERVICE

PZSM110006

PZSM130003

02

02–37

Chery Automobile Co., Ltd.

32. Disconnect the clutch cable (1) from the clutch

housing and position it aside.

33. Lower the vehicle and install engine lift chain hangers.

34. Remove the two front engine mount bolts (1) and

the four front engine mount bracket bolts (2).
(Tighten: Engine front mount bolt to 80 ± 5 N·m)

35. Remove the rear engine mount bolt (1) and the

three rear engine mount bracket bolts (2).
(Tighten: Engine rear mount bolt to 60 ± 5 N·m)

ON-VEHICLE SERVICE

PZSM080034

PZSM020032

PZSM020011

02–38

Chery Automobile Co., Ltd.

36. Remove the three left transaxle mount bolts (1)

and the three left transaxle mount bracket bolts (2).
(Tighten: Left transaxle mount bolt to 65 ± 5 N·m)

37. Using special tool CH-20001, remove the two right

engine mount bolts (1) and three right engine
mount bracket bolts (2).
(Tighten: Engine right mount bolt to 65 ± 5 N·m)

38. Verify all components between the engine and

vehicle are disconnected.

39. Remove the front sub-frame (See Front Sub-Frame

Removal & Installation in Section 10 Suspension).

40. Hoist the engine from the vehicle.

CAUTION:

Verify all electrical connectors are discon-

nected prior to engine/transaxle removal.

41. Separate the engine and transaxle.

42. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

PZSM020031

PZSM020006

02

02–39

Chery Automobile Co., Ltd.

Engine Timing Belt

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20001 - Right Engine Mount Bolt Remover

• CH-20003 - Crankshaft Holder

• CH-20010 - Camshaft Holder

• Engine Hoist

1. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).

2. Disconnect the negative battery cable.

3. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).

WARNING!

Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.

1 - Timing Belt Upper Cover Bolt

2 - Timing Belt Upper Cover

3 - Timing Belt Cover Gasket

4 - Timing Belt

5 - Timing Belt Touch Pulley

6 - Camshaft Bolt

7 - Camshaft

8 - Rear Timing Cover Bolt

9 - Rear Timing Cover

10 - Idler Pulley

11 - Tensioner Pulley

12 - Tensioner Pulley Bolt

13 - Timing Belt Lower Cover

14 - Timing Belt Lower Cover Bolt

15 - Timing Belt Upper Cover Bolt

ON-VEHICLE SERVICE

LTSM020162

02–40

Chery Automobile Co., Ltd.

4. Remove the coolant reservoir clamps (1) and set
aside.

5. Attach an engine hoist and support the engine using the engine hoist.

6. Using special tool CH-20001, remove the engine
right mount bolts (1) and bracket bolts (2).
(Tighten: Engine right mount bolts to 65 ± 5 N·m)

7. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).

8. Remove the six crankshaft vibration damper bolts
(1).
(Tighten: Crankshaft vibration damper bolts to 25 ±
5 N·m and an additional 30 ± 5°)

ON-VEHICLE SERVICE

PZSM110007

PZSM020006

BESM020055

02

02–41

Chery Automobile Co., Ltd.

9. Remove the timing belt upper cover (1) and the
timing belt lower cover (2).
(Tighten: Timing belt upper cover bolts to
8 ± 3 N·m)
(Tighten: Timing belt lower cover bolts to
8 ± 3 N·m)

10. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).

11. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).

12. Remove the plug in the cylinder block.

13. Using special tool CH-20003 (1), install the crank­shaft holder (1) into the cylinder block and rotate
the crankshaft until the crankshaft tool completely
holds the crankshaft in place.
(Tighten: Crankshaft holder to 28 N·m)

NOTE: The crankshaft holder will prevent the
crankshaft from rotating in either direction.

ON-VEHICLE SERVICE

BESM020020

BESM020015

02–42

Chery Automobile Co., Ltd.

14. Using special tool CH-20010 (1), install the cam­shaft holder to hold the camshafts in place.

NOTE: The camshaft holder will prevent the cam­shafts from rotating in either direction.

CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can cause
serious damage to the valves or pistons.

15. Loosen the bolt of the timing belt tensioner pulley
(1) and remove the pulley.
(Tighten: Timing belt tensioner pulley bolt to
27 ± 3 N·m)

16. Remove the timing belt (3).

NOTE :

When removing the timing belt, pay attention to the
operating direction of the timing belt. Refer to the oper­ating direction of the engine crankshaft and the arrow
head direction on the timing belt.

17. Installation is in the reverse order of removal.

Installation Notes:

• Install the timing belt and rotate the tensioner pul-

ley with an Allen wrench in order to apply tension
to the belt and align the finger pointer of the ten­sioner to the middle of the U-slot opening.

• Tighten the tensioner pulley bolt (1) to 27 ± 3 N·m.

• Tighten the intake and exhaust camshaft pulley

bolts (2 ) & (4) to 120 ± 5 N·m.

ON-VEHICLE SERVICE

BESM020016

PZSM020037

02

02–43

Chery Automobile Co., Ltd.

Exhaust Manifold

Removal & Installation

1. Remove the three bolts (1) attaching the exhaust
manifold heat shield.
(Tighten: Exhaust manifold heat shield bolts to
10 ± 5 N·m)

2. Remove the exhaust manifold heat shield.

3. Remove the three bolts (1) securing the exhaust
manifold to the catalytic converter assembly.
(Tighten: Exhaust manifold to the catalytic con­verter bolts to 60 ± 5 N·m)

4. Disconnect the catalytic converter assembly from
the manifold.

5. Remove the ten exhaust manifold nuts (1).
(Tighten: Exhaust manifold nuts to 20 ± 5 N·m)

ON-VEHICLE SERVICE

PZSM020024

PZSM020008

BESM020033

02–44

Chery Automobile Co., Ltd.

6. Remove and discard the exhaust manifold gasket
(1).

7. Installation is in the reverse order of removal.

Installation Notes:

• Clean all surfaces of manifold and cylinder head.

ON-VEHICLE SERVICE

LTSM020169

02

02–45

Chery Automobile Co., Ltd.

Intake Manifold

Removal & Installation

1. Disconnect the negative battery cable.

2. Remove the four spark plug wires (1) and set them
aside.

3. Remove the clamps (1) between the intake mani­fold and the air cleaner housing.

4. Remove the PCV return hose clamp (1) on the
intake manifold hose.

5. Remove the air intake hose.

ON-VEHICLE SERVICE

PZSM030016

PZSM020003

PZSM020046

02–46

Chery Automobile Co., Ltd.

6. Disconnect the manifold air pressure (MAP) sensor
electrical connector.

7. Remove the MAP sensor retaining bolt (1), and
then remove the MAP sensor.

8. Remove the intake manifold bracket retaining bolts
(1).

9. Remove the fuel vapor return hose (1) from the
throttle body.

ON-VEHICLE SERVICE

PZSM030004

PZSM020051

PZSM030018

02

02–47

Chery Automobile Co., Ltd.

10. Loosen the power steering pump adjustment bolt
(1).

11. Loosen the bolts (1) on the steering pump bracket.

12. Remove the A/C compressor belt.

13. Remove the steering pump (See Steering Pump Removal & Installation in Section 11 Steering).

14. Remove the A/C compressor (See A/C Compressor Removal & Installation In Section 13 Heating & Air Condi­tioning).

ON-VEHICLE SERVICE

PZSM020005

PZSM020050

02–48

Chery Automobile Co., Ltd.

15. Remove the four A/C compressor bracket retaining
bolts (1).

16. Remove the eight lower intake manifold retaining
bolts (1).
(Tighten: Lower intake manifold bolts to 8 ± 3 N·m)

17. Remove the lower intake manifold and gasket.

18. Remove and discard the intake manifold gasket.

NOTE :

Install a new intake manifold gasket during reassembly.

19. Installation is in the reverse order of removal.

Installation Notes:

• Clean all surfaces of manifold and cylinder head.

• Install new O-rings on the fuel injectors.

Oil Filter

Removal & Installation

NOTE :

The following special tools are required to perform the repair procedure:

• CH-10003 - Oil Filter Remover

WARNING!

Prolonged and repeated contact with engine oil will harm your skin. If engine oil is spilled on your skin, wash it
off immediately with water. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Always use adequate skin protection when performing vehicle service.

ON-VEHICLE SERVICE

PZSM020047

PZSM020010

02

02–49

Chery Automobile Co., Ltd.

CAUTION:
When servicing the oil filter, avoid deforming the filter by installing the special tool against the
base of the filter.

1. Using special tool CH-10003, remove the oil filter
(1).
(Tighten: Oil filter to 25 ± 3 N·m)

CAUTION: When removing the oil filter, ensure
that the oil filter gasket is not stuck to the
engine. The oil filter gasket must be removed
from the engine before installing the new oil fil­ter.

2. Installation is in the reverse order of removal.

Installation Notes:

• Lubricate the oil filter gasket ring with clean engine
oil.

• Clean all surfaces, and verify the oil filter does not
leak.

Oil Pan

Removal & Installation

1. Remove the oil dipstick.

2. Raise and support the vehicle.

3. Remove the oil pan drain plug and drain the engine oil.
(Tighten: Oil pan drain plug to 40 N·m)

NOTE :

Do not pry on cylinder block to remove oil pan.

4. Remove oil pan bolts (1).
(Tighten: Oil pan bolts to 18 N·m)

5. Using a putty knife, loosen the seal around the oil pan.

6. Remove the oil pan.

7. Installation is in the reverse order of removal.

ON-VEHICLE SERVICE

LTSM020206

LTSM020205

02–50

Chery Automobile Co., Ltd.

Installation Notes:

• Oil pan sealing surfaces must be free of grease or oil.

• Install the four oil pan corner bolts in the sequence shown (1-2-3-4).

• Install the remaining oil pan bolts.

• Torque all the oil pan bolts to the proper

specification.

Oil Pump

Removal & Installation

1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).

2. Remove the six crankshaft vibration damper retain­ing bolts (1).
(Tighten: Crankshaft vibration damper bolts to 25 ±
5 N·m and an additional 30 ± 5°)

3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).

4. Remove the crankshaft timing belt pulley bolt (2)
from the crankshaft.
(Tighten: Crankshaft timing belt pulley bolt to 130 ±
10 N·m and an additional 65 ± 5°)

5. Remove the key-way from the crankshaft.

6. Use an appropriate tool and remove the front
crankshaft oil seal (1).

ON-VEHICLE SERVICE

VISM020013

BESM020055

LTSM020199

02

02–51

Chery Automobile Co., Ltd.

7. Remove the four oil pump bolts (1).
(Tighten: Oil pump bolts to 8 ± 3 N·m)

8. Remove the oil pump (2) using a suitable tool.

9. Remove the oil pump gasket (3).

10. Installation is in the reverse order of removal.

Installation Notes:

• Before installing, prime the new oil pump. Fill the oil pump with engine oil and rotate the oil pump.

• Replace the oil pump gasket.

Oil Strainer

Removal & Installation

1. Raise and support the vehicle.

2. Remove the oil pan (See Oil Pan Removal & Installation in Section 02 Engine).

3. Remove the three oil strainer retaining bolts (1).
(Tighten: Oil strainer bolts to 18 N·m)

4. Carefully remove the oil strainer.

5. Installation is in the reverse order of removal.

Installation Notes:

• Install new O-ring on the oil strainer pipe.

ON-VEHICLE SERVICE

BESM020032

BESM020018

02–52

Chery Automobile Co., Ltd.

ENGINE UNIT REPAIR

Engine Block

Specifications

Torque Specifications

DESCRIPTION TORQUE (N·m)

Connecting Rod Cap Bolts

1st Step: Tighten the bolt to 25 ± 3 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°

Main Bearing Cap Bolts

1st Step: Tighten the bolt to 45 ± 5 N·m

2nd Step: Tighten the bolt an additional 180 ±10°

Lower Cylinder Block Bolts 20 ± 3

Cylinder Bore Specifications

DESCRIPTION SPECIFICATION (mm)

Surface Distortion Limit 0.15

Inner Diameter Standard 73.005 ± 0.005

Out-Of-Round Less than 0.008

Taper Less than 0.01

Disassembly

1. Remove the oil pan and then remove the oil baffle.

2. Remove the oil strainer.

3. For each connecting rod / piston assembly to be removed, rotate the crankshaft to the bottom dead center posi­tion for each cylinder.

NOTE :

Before removing the connecting rod / piston assembly, check the connecting rod side clearance.

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4. Remove the eight connecting rod retaining bolts.

5. Remove the connecting rod bearing cap.

6. Using a hammer handle or similar tool, push the
connecting rod / piston assembly (1) out through
the top of the cylinder block.

7. Remove the connecting rod bearings (See Con­necting Rod Removal & Installation in Section 02
Engine).

CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in
the correct order.

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8. Installation is in the reverse order of removal.

Inspection

NOTE :

All measurements should be taken with the engine block at room temperature, 21°C.

Engine Block

• Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.

• Examine block and cylinder bores for cracks or fractures.

• Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm.

Cylinder Bore

• The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cyl­inder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

• Measure the cylinder bore at three levels in directions X and Y. Top measurement should be 10 mm down and
bottom measurement should be 10 mm up from
bottom of bore.

CYLINDER BORE

All Cylinders 73.005 ± 0.005 mm

Assembly

NOTE :

Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any mate­rial created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause
engine failure.

NOTE :

Assemble all components in their original position.

1. Install the pistons to the connecting rods.

2. Using a piston ring expander, install the piston rings.

3. Assemble all components in the reverse order of disassembly.

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Pistons

Specifications

Clearance Specifications - Pistons

DESCRIPTION SPECIFICATION (mm)

Surface Distortion Limit 0.15

Inner Diameter Standard 73.005 ± 0.005

Out-Of-Round Less than 0.008

Taper Less than 0.01

Clearance Specifications - Piston Ring Groove

DESCRIPTION SPECIFICATION

First Ring 0.035 - 0.08 mm

Second Ring 0.025 - 0.07 mm

Clearance Specifications - Piston Ring End Gap

DESCRIPTION SPECIFICATION LIMIT

First Ring End Gap 0.2 - 0.4 mm 0.8 mm

Second Ring End Gap 0.4 - 0.6 mm 1.0 mm

Clearance Specifications - Piston to Piston Pin

DESCRIPTION SPECIFICATION

Piston To Piston Pin 0.002 - 0.013 mm

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Disassembly

• Piston Ring Removal

− Using a suitable ring expander, remove the
upper and intermediate piston rings.

− Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from
piston.

− Clean ring grooves of any carbon deposits.

CAUTION:
Before removing the piston rings (1), check the
piston ring side clearance. Be careful to mark
the location of the piston rings if they are to
be reused.

• Piston Pin Snap Ring Removal

− Using snap ring pliers, remove the snap ring
(1).

− Heat the pistons if necessary.

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• Piston Pin Removal

− Push out the piston pin with a suitable tool.

• Connecting Rod & Piston Disassembly

− Remove the piston from the connecting rod.

Inspection

Check the piston diameter.

PISTON DIAMETER

All Pistons 72.965 ± 0.009 mm

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Check the inner diameter of each cylinder bore (See
Cylinder Bore Inspection in Section 02 Engine).

CYLINDER BORE

All Cylinders 73.005 ± 0.005 mm

Check piston ring to groove side clearance.

• Clean the ring slot using a suitable tool.

• Measure piston ring to groove side clearance.

RING GROOVE CLEARANCE

First Ring 0.035 - 0.08 mm

Second Ring 0.025 - 0.07 mm

Check piston ring end gap clearance:

• Wipe the cylinder bore clean.

• Insert ring and push down with piston to ensure it

is square in the bore.

• The ring end gap measurement must be made with
the ring positioned at least 13 mm from bottom of
cylinder bore and below the bottom of the oil ring
travel where the cylinder bore has minimal wear.

• Check the ring end gap with a feeler gauge.

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RING END GAP CLEARANCE

First Ring 0.2 - 0.4 mm 0.8 mm

Second Ring 0.4 - 0.6 mm 1.0 mm

• Check the diameter of the piston pin bore.

• Check the outer diameter of the piston pin.

• Check the inner diameter of connecting rod (small end).

PISTON PIN CLEARANCE

Piston and Piston Pin 0.013 - 0.018 mm

Assembly

1. Install the piston to the connecting rod. Assemble the components in their original positions.

2. Using a piston ring expander, install the piston rings. Assemble the components in their original positions.

3. Assemble all components in the reverse order of disassembly.

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Connecting Rods

Specifications

Torque Specifications

DESCRIPTION TORQUE (N·m)

Connecting Rod Bolts

1st Step: Tighten bolts to 25 ± 3 N·m

2nd Step: Tighten the connecting rod bolts an additional

90 ± 5°

Clearance Specifications

DESCRIPTION SPECIFICATION

Connecting Rod Radial Clearance 0.023 - 0.058 mm

Connecting Rod Axial Clearance 0.15 - 0.4 mm

Disassembly

1. Remove the connecting rod cap bolts.

2. Remove the connecting rod bearing cap.

3. Using a hammer handle or similar tool, push the
piston and connecting rod assembly (1) out
through the cylinder head side of the engine block.

NOTE: Before removing the piston and connecting rod assembly, check the connecting rod side clearance.

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4. Remove the connecting rod bearings.

CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in
the correct order.

Inspection

• Check the radial clearance of the connecting rod bearings.

CONNECTING ROD RADIAL CLEARANCE

Radial Clearance 0.023 - 0.058 mm

Assembly

NOTE :

The rod bolts should not be reused.

1. Before installing the NEW rod bolts, the threads and under the bolt head should be oiled with clean engine oil.

2. Install each bolt finger tight, then alternately tighten each bolt to assemble the cap properly.

3. Tighten the connecting rod bolts using the two step
torque-turn method:

• 1st Step: Tighten bolts to 25 ± 3 N·m

• 2nd Step: Tighten the connecting rod bolts an

additional 90 ± 5°

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4. Using a feeler gauge, check connecting rod side clearance.

• Check axial clearance of connecting rod.

Crankshaft

Specifications

Torque Specifications

DESCRIPTION TORQUE (N·m)

Main Bearing Cap Bolts

1st Step: Tighten the bolt to 45 ± 5 N·m

2nd Step: Tighten the bolt an additional 180 ± 10°

Lower Cylinder Block Bolts 25 ± 5

Clearance Specifications

DESCRIPTION SPECIFICATION (mm)

Diameter of Crankshaft Main Journals 46.01

Diameter of Crankshaft Rod Journals 44.485 - 44.495

Out-of-Round Maximum of Crankshaft Main Journals 0.008

Axial Clearance of Crankshaft 0.02 - 0.30

Radial Clearance of Crankshaft 0.0035 - 0.034

Coaxality Crankshaft Main Journal 0.05

Thrust Washer Thickness 2.4 - 2.405

Disassembly

1. Remove the front crankshaft oil seal (See Front Crankshaft Oil Seal Removal & Installation in Section 02
Engine).

2. Remove the rear crankshaft oil seal (See Rear Crankshaft Oil Seal Removal & Installation in Section 02 Engine).

3. Remove the pistons with connecting rod assemblies.

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4. Remove the 20 lower cylinder block bolts in the
sequence shown.

NOTE: Before loosening the lower cylinder block
bolts, measure the crankshaft side clearance.

5. Remove the lower cylinder block.

6. Remove the crankshaft.

7. Remove the main bearings and thrust bearings from the upper cylinder block and lower cylinder block.
NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same position

and direction.

Inspection

Inspect the crankshaft rod and main journals for the fol­lowing:

• The crankshaft main journals should be checked for
excessive wear, roundness and scoring.

• Main journal limits of roundness should be held to

0.008 mm.

• Rod journal limits of roundness should be held to

0.005 mm.

CAUTION:
DO NOT nick the crank journals or bearing
fillets.

Check the axial clearance after installation:

• Standard axial clearance should be 0.02 mm.

• Limits of axial clearance should be held to 0.30

mm.

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Check oil clearance of crankshaft main and rod jour­nals:

• Clean the journal and bearing.

• Install the crankshaft.

• Cut the plastic-gauge to the same width as the

bearing, and then put it onto the crankshaft journal
to make it parallel with the central line of the crank­shaft.

• Install the main bearing cap carefully, and tighten
the bolts to the specified torque.

• Remove the main bearing cap.

• Measure the oil clearance with the plastic-gauge.

− Standard oil clearance of crankshaft rod and
main journals should be 0.02 mm

− Limits of oil clearance of crankshaft rod and
main journals should be 0.06 mm

Assembly

1. Install the main bearings and thrust bearings in the upper cylinder block and lower cylinder block.
NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and

direction.

2. Assemble the crankshaft and main bearings in the reverse order of disassembly.

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CYLINDER HEAD UNIT REPAIR

Cylinder Head

Specifications

Torque Specifications

DESCRIPTION TORQUE (N·m)

Cylinder Head Bolts

1st Step: Tighten the bolt to 50 ± 5 N·m

2nd Step: Tighten the bolt an additional 90 ± 5°

3rd Step: Tighten the bolt an additional 90 ± 5°

Cylinder Head Cover Bolts 8 ± 3

Clearance Specifications

DESCRIPTION SPECIFICATION (mm)

Cylinder Head Flatness 0.05 - 0.10

Intake Valve Deflection 0.02

Exhaust Valve Deflection 0.04

Spring Height 49.0

Disassembly

NOTE :

The following special tools are required to perform the repair procedure:

• CH-20018 - Valve Spring Compressor

• CH-20013 - Valve Seal Remover

• CH-20011 - Valve Seal Installer

• CH-20012 - Valve Stem Seal Installer Guide

• CH-20017 - Valve Keeper Installer

• CH-20010 - Camshaft Holder

NOTE :

Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts.

1. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine).

2. Remove the hydraulic tappet assembly (1).

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3. Using the special tool CH-20018 (1), compress the
valve spring.

4. Remove the valve keeper (1), valve spring retainer
(2) and valve spring (3).

5. Push the valve stem from the cylinder head and
remove the valve (4).

6. Using special tool CH-20013 (1), remove the valve
oil seal.

7. Remove the valve guide if necessary.

8. Remove the spark plugs.

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Inspection

Inspect the cylinder head for the following:

• Cylinder head must be flat within 0.05 - 0.10 mm.

• Inspect camshaft bearing journals for scoring.

• Remove carbon and varnish deposits from inside of

valve guides with a valve guide cleaner.

• Verify the valve tappets move freely in their bores,
and that they have been rotating.

• Check the valve guide height.

Assembly

1. Install new valve guide if necessary.

2. Install new valve seat if necessary.

3. Using special tool CH-20011 (1) & CH-20012 (2),
install the new valve oil seal.

4. Install the valves into the cylinder head (larger diameter on intake side).

5. Install the valve springs.

6. Install the valve spring retainers.

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7. Using a valve spring compressor CH-20018 (1),
compress the valve springs.

8. Install the valve keepers.

9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.

10. Install valve tappets in the head.

11. Install the camshafts.

Installation Notes:

• Coat the valve oil seals with engine oil.

Camshaft

Specifications

Camshaft Specifications

DESCRIPTION SPECIFICATION (mm)

Intake Cam Lobe Height 37.11

Exhaust Cam Lobe Height 37.09

Journal #1 Outer Diameter 31.934 - 31.95

Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96

Cam Bearing #1 Inner Diameter 32 - 32.025

Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021

Journal #1 Clearance 0.05 - 0.090

Journal #2, #3, #4, #5 Clearance 0.04 - 0.074

Intake Camshaft Axial Clearance 0.15 - 0.20

Exhaust Camshaft Axial Clearance 0.15 - 0.20

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Disassembly

1. Remove the camshaft bearing cap bolts.
NOTE: Equally loosen camshaft bearing cap bolts

in several steps.

2. Remove the camshaft bearing caps and place
them in proper order.

NOTE: The camshaft bearing caps are marked for
identification.

3. Remove the camshafts and then remove the cam­shaft seals.

Inspection

• Measure the camshaft cam lobe height.

• If wear is beyond the limit, replace the camshaft.

CAMSHAFT CAM LOBE HEIGHT

Intake Cam Lobe Height 37.11 mm

Exhaust Cam Lobe Height 37.09 mm

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• Measure the outer diameter of the camshaft
journal.

OUTER DIAMETER OF CAMSHAFT JOURNAL

Journal #1 Outer Diameter 31.934 - 31.95 mm

Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96 mm

• Measure the inner diameter of the camshaft
bearing.

INNER DIAMETER OF CAMSHAFT BEARING

Cam Bearing #1 Inner Diameter 32 - 32.025 mm

Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021 mm

• Calculation of camshaft journal clearance

Journal clearance = (inner diameter of camshaft bearing) - (outer diameter of camshaft journal)

CAMSHAFT JOURNAL CLEARANCE

Journal #1 Clearance 0.05 - 0.090 mm

Journal #2, #3, #4, #5 Clearance 0.04 - 0.074 mm

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